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5 Low-temperature steels
The large scale industrial use of oxygen in the steel industry, nitrogen in the chemical industry, and the
supply of natural gas to all industrial sectors, have become much more important in recent years. With
the increased use of these gases, their economical transport and storage has become more and more
important. The behaviour of gases, which change to a liquid state at low temperatures and so greatly
reduce their volume, is exploited here.
This property of gases can only be used if suitable base materials and welding consumables, which
have sufficiently good mechanical properties and are adequately tough at the low temperatures of
the liquid gases, are available for the construction of the necessary transport and storage containers.
Unalloyed, low-alloy or high-alloy steels that remain tough at low temperatures (e.g. below -50C)
are known as low-temperature steels. Unalloyed and low-alloy steels can in any case be used at
temperatures down to -50C.
These groups of steels can be distinguished:
1. Unalloyed or low alloy, low-temperature and fine-grained steels for operating temperatures down
to around -50C in a normalised state or down to about -60C in a quenched and tempered state.
2. Nickel alloy quenched and tempered steels with between 1.5 and 9% nickel for operating temperatures between -80C and about 200C.
3. Austenitic chromium-nickel steels for operating temperatures down to about -269C.
Welding low-temperature steels
The key property of welding consumables for welding cryogenic materials is their ability to change
shape at low temperatures. This is usually tested using the Charpy impact test. The value of the impact
energy allows conclusions to be drawn about the tendency to brittle fracture and the possibilities of use
down to a particular temperature.
The value of 27 joules with the Charpy V sample is often taken as the minimum value for the impact
energy at the lowest operating temperature applicable.
When welding low-temperature and fine-grained structural steels, controlled heat input must be ensured
in order to keep the zone affected by the heat as narrow as possible and yet to avoid hardness peaks.
Unalloyed and low-alloy basic coated types according to EN ISO 2560 and EN ISO 18275 are used for
the stick electrodes. It is necessary to ensure that the hydrogen content of the welded joint is as low as
possible in order to avoid cold cracking, which means that redrying the electrodes before welding, and
taking them from a heated quiver, is recommended.
This point also applies to the welding flux used in submerged arc welding. The necessary low-temperature
toughness and strength must be taken into account particularly when selecting wire-flux combinations
or wire-shielding gas combinations.
When unalloyed flux cored wires are used, basic or metal cored wires are to be preferred because
of the toughness and the low diffusible hydrogen content.
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482
483
484
Designations
16Mo3
13CrMo4-5
10CrMo9-10
X10CrMoVNb9-1
BHLER FOX C 9-MV, Thermanit CrMo 9V, BHLER C 9 MV-IG, Thermanit MTS 3, BHLER C 9 MV-UP
P92, NF 616
X20CrMoWV12-1
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486
This means that it is possible to distinguish between ferrite-forming and austenite-forming elements,
as follows. Ferrite-forming elements: chromium, silicon, aluminium, molybdenum, niobium, titanium,
tungsten and vanadium.
Austenite-forming elements: nickel, manganese, carbon, cobalt, copper and nitrogen. If sufficient quantities of nickel are added to a ferritic iron-chromium alloy, it converts to the austenitic state.
The most important groups of stainless steels are listed in the following table. They are divided according to the microstructure.
Microstructure
Material types
Pearlitic-martensitic
X30Cr13
Semi-ferritic-ferritic
X8Cr17
Soft martensitic
X5CrNi13-4
Ferritic-austenitic
X2CrNiMoN22-5
Austenitic
Austenite with ferrite
Austenite without ferrite
X5CrNi18-9
X8CrNiNb16-13
These steel groups differ both from the metallurgical and the physical point of view, and suitable
measures must be taken when welding to allow for their special features.
%C
%Cr
%Mo
Welding suitability
X12Cr13
0,15
13,0
limited
X20Cr13
0,20
13,0
very limited
X39CrMo17-1
0,42
16,5
1,2
none
Basically this group of steels must be considered as having only limited suitability for welding. As the
carbon content rises, the risk of cold cracking increases, and joint welding should be avoided as far as
possible.
The most important alloying element is chromium which, when the content is about 12%, lends its passivity, and therefore its corrosion resistance in oxidising media, to the steels. As a ferrite-forming element,
chromium restricts the austenite region of the iron; with about 13% chromium it is entirely choked off.
Steels with chromium contents of greater than 13% and with very low carbon contents (< 0.1%) do not
undergo any conversion as they cool from the solidification temperature to room temperature. These
are the ferritic Cr steels.
The group of hardenable steels begins at chromium contents above 12% and carbon contents of about
0.1 to 1.2%. These are the martensitic chromium steels. As a result of the higher-carbon content, the
austenite region is extended, and this creates the possibility of hardening.
Welding martensitic chromium steels
The austenitic component in the heat affected zone of the base material is always converted to martensite with air cooling, since the formation of pearlite and intermediate phases is heavily delayed by the
high chromium content.
Due to the high chromium content of the steel, the conversion to pearlite, in which the delta-ferrite and
the carbide are precipitated from the gamma solid solutions, only begins after a very long time. As a
result, the weld metal, and the heat affected zone (HAZ), effectively always convert to the martensitic
phase, unless it is heated above the martensite conversion temperature.
If we consider the increasing hardness of this kind of steel in relation to the carbon content, their unfavourable or inadequate suitability for welding can easily be understood.
Increase in hardness for various carbon contents:
Carbon content
Hardness
0.10% C
0.15% C
0.20% C
0.25% C
0.40% C
0.70% C
1.00% C
ca. 40 HRC
ca. 46 HRC
ca. 50 HRC
ca. 53 HRC
ca. 56 HRC
ca. 58 HRC
ca. 60 HRC
At the same time we can also understand that, in practice, martensitic Cr steels with less than
0.15% carbon are almost the only ones used for welded constructions.
The role played by hydrogen during welding represents a further disadvantageous factor.
Particularly when brittle martensite is present, higher hydrogen contents can lead to a strong tendency
to hydrogen-induced cold cracking in the welded joint.
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488
Designation
Same Type
BHLER SKWAM-IG
Dissimilar
%C
%Cr
%Mo
Welding suitability
X6Cr13
<0,08
13,0
limited
X6Cr17
<0,08
17,0
limited
X6CrMo17-1
<0,08
17,0
1,1
limited
A fine-grained structure is a precondition for adequate technical parameters, particularly where elongation is concerned. This is achieved if the last conversion stages are carried out below 800C, with
subsequent heat treatment up to 800C followed by fast cooling in air or water. This group of materials
is very sensitive to overheating. If exposed to temperatures above 1000C, the grains tend to become
coarser and this, in combination with carbide precipitation, can result in heavy embrittlement. Ferritic Cr
steels are therefore also not used for the construction of pressure vessels.
In addition, the ferritic Cr or Cr-Mo steels tend, as the Cr content rises, to exhibit a time-dependent
hardening phenomenon in the temperature range between 400 and 525C. This is known as 475C
embrittlement. It involves a separation of the ferrite into a high-chromium and a high-iron phase.
Welding ferritic Cr steels
Particularly in the case of steels with a high Cr content, the heat introduced during welding causes
grain growth in the highly heated part of the transition zone, and this cannot be rectified by subsequent
heat treatment. In addition, carbide is precipitated at the grain boundaries, leading to a further reduction
of toughness. For these reasons, the ferritic Cr steels are classified as having only limited suitability
for welding. Similarly unfavourable conditions are to be expected in the weld metal when same type
welding consumables are used.
The loss of toughness constitutes an absolute weakening of the welded joint. The use of austenitic
welding consumables is therefore recommended for welding ferritic Cr steels.
Due to its altogether greater toughness, the austenitic weld metal is able to act to some extent as an
expansion element. The austenitic weld metal also offers advantages from the point of view of corrosion
chemistry. There is a disadvantage in the form of the different colouring of the base material and the
weld metal. If colour matching is a necessity, same type alloy welding consumables must be used. If gases containing high amounts of sulphur or carburising gases will be present in practice, it is possible that
the austenitic weld metal will be attacked preferentially (e.g. through the formation of nickel sulphide).
In this case, the procedure is to fill the joint with austenitic metal, and to weld only the last layers of the
medium exposed surfaces using ferritic welding consumables. Welding is carried out after preheating
to between 200 and 300C, in order to keep thermal stresses as low as possible. Care is to be taken
to introduce as little heat as possible, in order to minimise the formation of coarse grains. Annealing in
the range from 700 to 750C is advantageous after welding. This causes the precipitated carbides to
coagulate, whilst reducing tensions at the same time. Up to a certain point, both of these factors bring
an improvement in toughness.
The coarse grains in the heat affected zone cannot, however, be overcome. When austenitic welding
consumables are used, it is necessary to allow for their tendency to precipitate intermetallic phases
(embrittlement) in the temperature range between 600 and 900C.
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490
Microstructure
Designation
Dissimilar
%C
%Cr
%Mo
%Ni
Welding suitability
X5CrNi13-1
<0,05
13,0
0-0,4
1 - 1,2
good
X5CrNi13-4
<0,05
13,0
0,4
4,0
good
X5CrNi13-6
<0,05
13,0
0,4
6,0
good
X5CrNi16-6
<0,05
16,0
6,0
good/ limited
X5CrNiMo16-5-1
<0,05
16,0
1,5
5,0
good/ limited
This kind of material exhibits a very wide range of mechanical properties, depending on its chemical
composition and, above all, on the type of heat treatment. For this reason, only the X5CrNi13- 4 type
will be considered closely in what follows.
The basic ideas behind the development were, firstly, to lower the carbon content in order to increase
the toughness of the martensitic structure and to reduce the tendency to cold cracking, whilst achieving
a microstructure as free as possible from delta-ferrite by alloying with between 4 and 6% nickel.
At room temperature the microstructure thus consists of soft martensite with small quantities of supercooled delta-ferrite and austenite. Tempering further increases the toughness and lowers the hardness or strength. At the same time, the low carbon content and the inclusion of about 0.5% molybdenum
in the alloy increase the corrosion resistance.
A significant advantage of the soft martensitic chromium-nickel steels lies in their good suitability for
welding when compared with plain chromium steels.
The suitability of the soft martensitic steels for welding is largely characterised by three properties:
1.
2.
3.
The formation of low-carbon, tough martensite in the HAZ and in the weld metal, thus greatly
reducing the tendency to cold cracking.
A low delta-ferrite content. To a large extent this counters the tendency to form coarse grains
when welding.
The sensitivity of the martensitic microstructure to hydrogen. Hydrogen-induced cold cracking
can occur if the content of diffusible hydrogen is > 5 ml / 100 g.
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1.
2.
3.
4.
Only same type alloy welding consumables should be used for joining.
Covered electrodes and SAW flux are to be redried in accordance with the manufacturers specifications in order to maintain a hydrogen content of < 5 ml/100 g in the weld metal.
Thick walled components should be preheated to 100C, and welded using an interpass temperature in the range between 100 and 160C.
Tempering, or quenching and tempering is required after welding in order to increase toughness.
Sensitisation, i.e. a reduction in the resistance to corrosion due to the formation of chromium
carbide.
Hot cracking, i.e. separation of grain boundaries during solidification, or in the highly heated HAZ
when rigidly fixed.
Embrittlement, i.e. the precipitation of intermetallic phases such as the sigma phase through
exposure to high temperatures or annealing.
When welding the fully austenitic steels, their inherent tendency to hot cracking must also be considered.
Notes on the welding techniques for standard austenitic Cr-Ni-(Mo) steels, the subsequent heat treatment of the weld seams, and information on welding consumables can be found in the corresponding
sections.
Welding technology
Only grades corresponding to the base material concerned should be used for welding. The delta-ferrite content of the weld metal should be in the range between 3 - 15 FN (ferrite number). This
ensures sufficient resistance to hot cracking. For highly corrosion-resistant special steels, same
type welding consumables that yield a fully austenitic weld metal are also available.
Ensure that austenitic steels are only processed when their surface is clean and dry.
The arc should be kept as short as possible in order to avoid picking up nitrogen from the air.
When welding with shielding gas, it is necessary to make sure that the gas shield is working
perfectly. With the exception of flux cored wire welding, only shielding gases with a low CO2
content should be used in order to keep carburising of the weld metal to the lowest possible level.
Preheating to 100 - 150C is only advisable if the base material is thick, but it is not necessary
in principle.
An interpass temperature of 150C should not be exceeded.
Ensure that the current intensity is kept within the recommended range.
If it is not possible to reweld the root when welding with shielding gas, then shielding gas (e.g.
forming gas or pure argon) must be applied from the rear.
If possible, dilution with the base material should be kept below 35%. If, as a result of the welding
method, it is higher than this, the ferrite content of a test seam must be determined with a calibrated ferrite content meter or an estimate must be calculated from the chemical composition, e.g.
using the WRC-92 diagram. The ferrite content, i.e. the FN, should not be below the minimum
figure mentioned above.
Annealing treatment after welding should be avoided at all costs. If this is not possible, then it
must be expected that the corrosion resistance and/or toughness may be impaired. In such cases
consultation with the manufacturer of the steel and of the welding consumable is recommended.
In general it is possible to use unstabilised, low-carbon welding consumables for stabilised steels
and vice versa, but the temperature limit for intergranular corrosion must be borne in mind.
Greater distortion than when welding ferritic steels must be allowed for, and corresponding countermeasures, such as the seam shape, stronger tacking, pre-stressing, back-welding and so forth
must be considered.
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Straightening with the gas flame should not be done if at all possible, as corrosion resistance
can suffer from this. The harmful effect of arc strikes outside the welded joints should also be
particularly stressed in this context.
Only slag hammers and brushes of stainless Cr or Cr-Ni steels should be used for cleaning
austenitic welded joints.
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If the pickled component will soon be exposed to corrosive agents, as is frequently true for repair jobs,
then passivation is recommended after the pickling. Thorough rinsing is again necessary after the passivation treatment. While we are talking about the application of pickling agents, it is important to stress
that these are highly caustic substances. It is therefore essential that protective gear such as rubber
gloves, rubber aprons, eye protection and possibly breathing protection are used. Local environmental
protection regulations must also be observed.
Blasting with quartz, corundum or glass beads is used when grinding or pickling are not possible. This
method must only be applied using the said materials. The method does yield a clean, metallic surface,
but one that is somewhat rough. Passivation should also be carried out after blasting.
Welding consumables
The following table provides examples of various Bhler welding consumables that are appropriate for
welding the materials under discussion:
Material
Designation
X5CrNi18-9
BHLER FOX EAS 2-A (IG/UP/FD), Thermanit JEW 308L-17, Avesta 308L/MVR
X2CrNi18-9
BHLER FOX EAS 2-A (IG/UP/FD), Thermanit JEW 308L-17, Avesta 308L/MVR
X5CrNiMo18-12
BHLER FOX EAS 4 M-A (IG/UP/FD), Thermanit JEW 316L-17, Avesta 316L/MVR
X2CrNiMo18-10
BHLER FOX EAS 4 M-A (IG/UP/FD), Thermanit JEW 316L-17, Avesta 316L/MVR
X10CrNiNb18-9
X10CrNiMoNb18-10